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Abstract:

A method of repurposing dual-paned insulated glass window units (IGUs)
that would otherwise be put to waste into thermal solar panels capable of
generating hot water for a residence or other structure. The method
includes the steps of removing an existing IGU, disassembling and
cleaning the IGU, and reassembling the IGU with a new silicon seal and
fluid channels for connection to a looped solar heating system. The space
between the panes may be filled with a liquid to be heated by solar
radiation, or alternatively by a conduit which transports the liquid
through the panel.

Claims:

1. A method of manufacturing a solar panel from a glass unit with spaced,
double glass panes connected by a perimeter seal, which method comprises
the steps of:forming an opening in said seal;installing a fluid
connection through said seal between the exterior and interior of the
glass unit; andresealing said seal at said fluid connection.

2. The method according to claim 1 wherein said glass unit comprises a
used glass unit, which method includes the additional steps
of:disassembling said glass unit by opening said seal;cleaning said glass
panes;resealing said glass unit at the glass unit perimeter; andadapting
said solar panel for fluidic connection to a solar heating system loop.

3. The method according to claim 2, which includes the additional steps
of:placing a length of pipe in said solar panel interior between said
panes; andconnecting said pipe to said fluid connection.

4. A method of repurposing an insulated thermal glass window unit
comprised of an interior pane with an interior and exterior surface, an
exterior pane with an interior and exterior surface, an interior space
between said panes being faced by said interior face of each of said
panes, and a gasket sealing all edges of the two panes around said
interior space into a solar heat energy absorbing panel, which method
comprises the steps of:at least partly disassembling the thermal glass
window unit;opening the gasket;inserting first and letter second pipe
sections through said gasket at first and second locations on a perimeter
of the unit;resealing the edges of said panes and providing a fluid tight
seal around the interior space and around said inserted pipe
sections;placing a frame around the perimeter of the unit;attaching
insulation to said exterior face of said formerly exterior glass pane to
form a bottom surface to the solar panel; andforming a fluid-conducting
space between said panes adapted for receiving lower-temperature fluid
from the first pipe section and discharging heated fluid from the second
pipe section.

5. The method of claim 4, which includes the additional step of painting
said internal face of said internal pane with a solar radiation-absorbing
black paint.

6. The method of claim 5, which includes the additional step of painting
said internal face of said external pane with a solar radiation-absorbing
black paint.

7. A method of repurposing an insulated thermal glass window unit
comprised of an interior pane with an interior and exterior surface, an
exterior pane with an interior and exterior surface, an interior space
between said panes being faced by said interior face of each of said
panes, and a gasket sealing all edges of the two panes around said
interior space into a solar heat energy absorbing panel, which method
comprises the steps of:at least partly disassembling the thermal glass
window unit;opening the gasket;placing a conduit for circulating a liquid
between the panes of said unit;extending the ends of said conduit through
openings in the glass unit sealing means at first and second locations on
a perimeter of the unit;resealing the edges of said panes and providing a
fluid tight seal around the interior space and around said inserted
conduit extending past the pane edges;placing a frame around the
perimeter of the unit; andattaching insulation to said exterior face of
said formerly exterior glass pane to form a bottom surface to the solar
panel.

8. The method according to claim 4, which includes additional steps
of:acquiring discarded glass units;training individuals on how to
disassemble, clean, and repurpose said acquired glass units into useable
thermal solar panels;training individuals to install said repurposed IGUs
into new or existing solar heating system loops; andinstalling said
repurposed units in said solar thermal heating system loops.

9. The method according to claim 4, which includes the additional steps
of:providing common, unitary parts designed to quickly and effectively
repurpose a used glass unit into a working thermal solar panel;
andsupplying end-users with said common, unitary parts.

10. The method according to claim 4, including:licensing the technology of
repurposing used glass units to other individuals; andsupplying said
individuals with said common, unitary parts for quickly converting a
glass unit into a working thermal solar panel.

11. The method according to claim 4, including:transforming captured
thermal energy into electricity for common usage; androuting said
electricity into the attached structure's electrical system.

12. The method according to claim 4, which includes the additional step of
painting said internal face of said internal pane with a solar
radiation-absorbing black paint.

13. The method according to claim 4, which includes the additional step of
painting said internal face of said external pane with a solar
radiation-absorbing black paint.

14. The method according to claim 7, which includes additional steps
of:acquiring discarded glass units;training individuals on how to
disassemble, clean, and repurpose said acquired glass units into useable
thermal solar panels;training individuals to install said repurposed IGUs
into new or existing solar heating system loops; andinstalling said
repurposed units in said solar thermal heating system loops.

15. The method according to claim 7, which includes the additional steps
of:providing common, unitary parts designed to quickly and effectively
repurpose a used glass unit into a working thermal solar panel;
andsupplying end-users with said common, unitary parts.

16. The method according to claim 7, including:licensing the technology of
repurposing used glass units to other individuals; andsupplying said
individuals with said common, unitary parts for quickly converting a
glass unit into a working thermal solar panel.

17. The method according to claim 7, including:transforming captured
thermal energy into electricity for common usage; androuting said
electricity into the attached structure's electrical system.

18. The method according to claim 7, which includes the additional step of
painting said internal face of said internal pane with a solar
radiation-absorbing black paint.

19. The method according to claim 7, which includes the additional step of
painting said internal face of said external pane with a solar
radiation-absorbing black paint.

[0003]The present invention relates generally to a method of adapting and
repurposing used, spoiled, or excess thermal window glass units that
would normally go to waste, into inexpensive new thermal solar energy
collecting panels for the purpose of generating product hot water or for
other heating or energy generation purposes.

[0004]2. Description of the Related Art

[0005]Thermally insulated dual pane windows have been used in new
construction and remodeling for some years now. Typically, building codes
mandate the use of such windows to reduce energy loss from homes and
other buildings. Conditioning of air with fossil energy, whether the air
is heated or cooled, can be wasted through contact with highly thermally
conductive glass doors and windows. Heated air inside will be cooled due
to cooler temperatures outside of a building, the heat energy being
transferred conductively through cold glass windows and doors. Similarly,
cooled air inside will be heated by contact with warmer glass exposed to
hot temperatures outside. This temperature loss in buildings is typically
most pronounced at windows and doors as walls are easier to insulate than
openings. In the past, windows and sliding glass doors were single-pane
glass, with a very low thermal resistance value (R value). Untreated
glass is a good conductor of heat energy. Thermally insulated windows and
glass doors improve the R value significantly and save a considerable
amount of heating and cooling energy compared to single pane windows and
sliding glass doors over the useful life of a building.

[0006]Glass "E" coatings can be applied in the manufacturing process to
different faces of thermal window glass to increase their insulation
effectiveness. These coatings can be designed to either reflect or absorb
long-wave solar radiation, depending on the window design and the desired
results. Reflecting thermal solar radiation will help to keep the
interior of a structure cooler in the summer, while absorbing solar
radiation will help to keep the interior warmer in the winter.

[0007]Thermal windows are formed by holding two or more panes of glass in
a frame in way that they do not touch each other, thus avoiding
conduction of heat energy from one glass pane to the other. The gap
between the panes of glass is filled with a gas for increasing the
thermal insulation of the window panes from each other. These spaces are
sealed air-tight along the perimeter edges of the glass panes with a
rubber like seal or gasket. In practice, the glass portions of thermal
windows are often referred to in the industry and in this document as
"Insulated Glass Units" or "IGUs." IGUs come in many dimensions from many
manufacturing firms. An IGU held in a frame is an insulated window or
insulated sliding glass door.

[0008]IGUs are limited to a useful lifespan of approximately twenty years.
As the IGU ages, humid air enters the space between the window panes as
the rubber gasket deteriorates and barometric pressure varies, resulting
in a pumping effect. Higher atmospheric pressure squeezes the glass panes
together, and lower atmospheric pressure relaxes the squeeze effect
creating a partial vacuum, thus "pumping" humid atmospheric gas into the
space between the glass panes through tiny leaks in the seal. Humidity
within the space between the glass panes can build up, causing water to
condense on the inner glass surfaces. Sodium bentonite granule packets or
similar water absorbing materials may be hidden in the window frame of
higher-grade IGUs to absorb such atmospheric humidity. This dehumidifying
effect lasts until the water absorption material reaches its maximum
water holding capacity. The trapped humid air eventually creates a fog
which condenses on the sealed interior glass surfaces. This creates an
unsightly foggy deposit that is quite visible, unattractive, and nearly
impossible and extremely uneconomical to clean and correct. Additional
wasted IGUs are a result of updating structures with newer, more
efficient thermal window units.

[0009]Although it is theoretically possible to disassemble the thermal
window, remove the rubber gasket, separate and clean the glass panes and
reform the IGU with fresh gasket materials, such efforts are laborious
and mechanically difficult and thus economically ineffective. It is
difficult to adequately clean the interior glass surfaces, (which
develops a well attached lime like deposit) install a fresh, functional
gasket, re-introduce inert gas between the panes, while at the same time
fully remove potentially humid air. Without the proper working conditions
and equipment, this becomes an impractical exercise. While some
procedures to clean the IGUs have even been patented, the practical
solution in the glass industry remains removing and disposing of the old
IGU and replacing it with a new IGU. Even when IGUs are disassembled and
cleaned, such cleaning procedures are not always successful and the
deterioration of the gasket is generally not addressed by cleaning
procedures.

[0010]The result is that many spoiled IGUs with fog and/or lime deposits
on the interior surfaces between the panes of glass are normally wasted
and replaced with new IGUs. Even recycling the used glass in old IGUs by
melting them down is frustrated due to contamination of such glass by the
well attached rubber gasket, which is very hard to fully remove and the
"E" coatings on the glass are also considered contaminants. Bits of
rubber gasket contamination in a large batch of molten glass spoils the
entire batch for most uses. Consequently, most IGUs are discarded. Glass
industry experts project that as many as 10,000,000 used IGUs are
discarded every year in the United States. Discarding used glass units
also wastes the energy it takes to replace them. Even melting used glass
down and re-using it as molten glass only saves about 50% of the energy
required to cast new glass and is problematic as stated above. Adding to
the mass of spoiled and used IGU introduced to the landfills are older,
functioning IGUs which are being replaced with more modern or more
efficient windows by the window replacement industry.

[0011]Thermal solar panels used to heat domestic water consist of a glass
cover plate, a thermal collector plate, a fluid circulation channel
attached to the collector plate, an encompassing frame and gaskets to
hold the panel parts together and typically, insulation behind the solar
panel to prevent thermal losses through the back of the panel that would
otherwise be captured by the collector. Thermal solar panels trap and
transform long wave heat energy from the sun into useable hot water.
Thermal solar panels are at the forefront when considering economic
renewable energy sources and sustainable building practices. Using
thermal solar panels to decrease the required heat energy that is
consumed in a building, without relying on the burning of limited fossil
fuels, is a step towards reducing carbon emissions and eliminating energy
waste.

[0012]Solar panels operate by absorbing long wave heat energy in the sun's
rays. To do this, a solar panel generally employs a flat or matt textured
dark substance as a collector plate which is better suited for absorbing
solar radiation than a light-colored, reflective substance. Thermal solar
panels can be made of any heat conducting dark substance.

[0013]A typical solar hot water installation, often referred to as a
"thermal solar system", uses heat energy from the sun to heat a fluid,
which is in turn used to move heat collected in the panel array to be
concentrated in a fluid heat storage vessel or tank. The process involves
progressively heating a body of water in a hot water tank. Solar hot
water panels are installed on the rooftop or other suitable location with
access to direct sunlight. Each panel contains a dark colored absorber
plate complete with fluid circulation means in conductive contact with
the plate. Thermal Solar systems commonly provide supplemental heat as
the water tanks used for storage of the product hot water are typically
electric or gas heaters to provide hot water at all times. Solar panels
can't collect heat energy without direct access to sunlight, and so the
thermal solar system heats the water when sunlight is available, and the
electric or gas system heats the water when sunlight is absent. Thermal
solar heat energy collected from panels may be used to heat hot water,
heat air, heat a building slab for radiant heating or other purposes.

[0014]The fluid circulation loop means includes a pipe system running from
the storage tank to the panels and back from the panels to carry the
heated water or heated thermally conductive fluid from the solar panel
array to a place where it can be stored or used. Hotter water from the
solar array tends to rise to the top of the storage tank and cooler water
tends to sink to the bottom of the storage tank. Cooler water from the
bottom of the tank is sent to the solar array. This effect of convection
in the water column tends to concentrate heat energy. A small electrical
circulation pump controlled by an electronic differential controller
powers the circulation loop that concentrates the heat. A heat exchanger
may be employed in the loop to transfer heat from the hot circulating
thermal fluid, such as glycol/water or oil and then circulate the cooled
thermal fluid back to the solar hot water array to be reheated. The
product hot water is in conductive contact with surfaces in the heat
exchanger and is thus progressively heated. The use of a heat exchanger
is advantageous during freezing weather because a glycol/water fluid is
less susceptible to freezing, whereas product tap water might freeze
within the panels, causing it to burst due to expansion. However, any
transfer of heat across a heat exchanger will slightly lower the
efficiency of the system, and this loss of efficiency must be taken into
account.

[0015]Food grade glycol with positively charged carbon in suspension may
be a heat absorbing member or collector plate of a solar panel. Food
grade corn Glycol offers advantages in case a leak in the heat exchanger
allows some glycol to enter the potable water. A person who accidentally
ingests diluted food grade glycol will not suffer injury as might occur
with regular glycol. Anti-freeze as the heat absorption fluid protects
the panels from damage in freezing weather but slightly reduces the
effectiveness of plain water. Oils may also be used for the thermally
conductive fluid in a thermal solar installation.

[0016]The loop cycle of heating the fluid, thermal energy extraction, and
sending the cooler fluid back to absorb more heat energy is begun anew
with each sunrise and lasts throughout the solar day for the effective
life of the thermal solar hot water system. A heat sensor on the panel
array is wired to operate the electrical differential controller device
used to turn off the electrical circulation pump when the sun goes down
or when the heat in the tank exceeds the temperature of the panel array.
Alternatively, a small photovoltaic solar panel may be used to power the
fluid circulation pump when solar energy is available.

[0017]It would be economically and environmentally advantageous to make
good use of previously unusable spoiled IGUs currently being placed in
landfills by converting them into inexpensive solar energy collecting
panels. Heretofore, there has not been a method described like the one
presented here.

SUMMARY OF THE INVENTION

[0018]In the practice of the present invention, a used or excess new
insulated thermal window is repurposed to act as a thermal solar panel.
The process of repurposing the window unit requires disassembly of the
old window, identifying and marking the former inside facing pane of
glass, then removing at least one side of the gasket holding the windows
panes together, installing a conduit, heat exchanger fluid, or pouring a
solid black body substance, such as an asphalt plate, with fluid
circulation means between the glass panes, then resealing the glass panes
and framing the glass sandwich with a new miter cut extruded aluminum
with mastic seal, insulating the back of the solar panel and adding a
backing plate completes the process. The gasket does not have to be
removed, and alternatively holes can be drilled into the gasket for
filling the internal space. The solar energy collection surface is in
thermally conductive contact with a fluid loop passage provided between a
hot water storage tank and the panel array. For conversion from using an
IGU in a building as a glazing member to use in a solar panel, in the
disclosed invention, the glass should be inverted to orient the "E"
coatings in such a way as they help rather than hinder the heat energy
absorbing process. The face of the (insulated glass unit) IGU that was
facing inside the building is oriented to face the sun when the IGU is
used as a solar panel.

[0019]One embodiment of the invention relates to filling the gap between
the glass panes of an old IGU with a glycol/water fluid with positively
charged carbon black particles in suspension. Another embodiment of a low
tech, inexpensive collector plate might be a long length of flexible
tubing inserted between the panes of glass and then a dark liquid asphalt
or resin material is poured in liquid form to harden in the remaining
space between the glass panes. Thus the collector plate, which is
commonly relatively costly copper plate or foil with copper tubing
soldered on for circulation means, is replaced with a black fluid or
inexpensive material which directly absorbs the heat energy at the solar
panel and transmits the collected energy when the fluid is looped back to
a heat exchanger in conductive contact with the product water. The tubing
might be an inexpensive high temperature extruded plastic tube instead of
costly copper tubing. The relatively poor conductivity of the plastic
tube material as compared to highly conductive copper is overcome by
adding considerably more length in the case of the plastic. The added
soft tube length also offers a large soft potentially compressible mass
within the glass gap which would help prevent freezing damage due to the
expansion of almost any material used in the collector plate. The soft,
but strong, silicone seal holding the solar panel together also allows
for expansion of the gap between the glass elements without breaking the
plate glass. Even aquariums are constructed of such silicone sealant and
glass alone. Some silicone sealants are designed for long term exposure
to UV radiation and high heat without losing the flexible but strong
adhesiveness of the material cured on glass surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]The drawings constitute a part of this specification and include
exemplary embodiments of the present invention and illustrate various
objects and features thereof.

[0021]FIG. 1 is a diagram showing a repurposed insulated thermal window as
a thermal solar panel being placed in an environment and inter-connected
to a circulation pump and hot water storage tank.

[0022]FIG. 2 is a cross-sectional view of a repurposed insulated thermal
window unit, demonstrating the interaction between the various layers
present after the unit is repurposed into a thermal solar panel.

[0023]FIG. 3 is an isometric view of a repurposed insulated thermal window
unit showing a sealed pair of glass panes with an exposed edge, and
demonstrating how a thermal solar panel is formed from the repurposed
window unit.

[0024]FIG. 4 is an isometric view of a repurposed insulated thermal window
unit showing the interaction and construction of the various layers
necessary to create thermal solar panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Introduction and Environment

[0025]As required, detailed aspects of the disclosed subject matter are
disclosed herein; however, it is to be understood that the disclosed
aspects are merely exemplary of the invention, which may be embodied in
various forms. Therefore, specific structural and functional details
disclosed herein are not to be interpreted as limiting, but merely as a
basis for the claims and as a representative basis for teaching one
skilled in the art how to variously employ the present invention in
virtually any appropriately detailed structure.

[0026]Certain terminology will be used in the following description for
convenience in reference only and will not be limiting. For example, up,
down, front, back, right and left refer to the invention as orientated in
the view being referred to. The words, "inwardly" and "outwardly" refer
to directions toward and away from, respectively, the geometric center of
the aspect being described and designated parts thereof. Said terminology
will include the words specifically mentioned, derivatives thereof and
words of similar meaning.

[0027]Thermal solar collectors are theoretically merely a heat energy
absorbing member exposed to thermal radiation from the sun that is in
conductive contact with fluid to be heated. Solar panels typically employ
new glass similar to that used in the new thermal windows mentioned
above, but may be a special low lead type solar glass, which only
slightly increases solar heat energy absorption. Solar panel construction
is always a trade off comparing the cost of parts versus the
effectiveness and life expectancy of the resulting solar panel. A
slightly less efficient panel sold at a much reduced price is
economically desirable. Often there is unused space to mount additional
solar panels in a typical solar installation to bring the total BTU yield
up to the required level. The actual yield of BTUs per dollar spent is a
valid basis upon which solar panels are rated. For example, a solid gold
solar energy collector plate with diamond parts might be the most
efficient solar panel possible per square inch, but would also be the
most costly solar panel imaginable. However, copper or aluminum plates
are fairly close to gold or silver collector plates in their ability to
conduct heat energy. Even copper use is reduced whenever possible due to
material cost considerations. New low-lead glass versus old plate glass
is a similar cost/performance consideration. While brand new low lead
solar glass might increase panel efficiency slightly compared to a used
IGU made with common plate glass or tempered glass, the cost comparison
for the BTU yield makes the used IGUs economically desirable. Reducing
the cost of solar thermal panels is a well known goal of the solar
industry and government agencies.

[0028]Some "solar panels" are a set of silicone cells which are solid
semiconducting wafers, connected electrically to one another. Solar
panels producing electricity do not function in the same manner as
hot-water producing solar panels, but the present invention can repurpose
thermal windows into a useable protective guard to contain electrical
photovoltaic solar panels. A thin film photovoltaic material may be
placed inside the open space in an old IGU to protect them from damage
and provide a protected rigid mounting surface. Alternatively, the
above-mentioned silicone cells may be placed directly between the two
glass panels, shielding them from damage. However, the preferred
embodiment of the present invention focuses on repurposing IGUs for
heating water.

[0029]In addition to the advantages to the environment and the economic
advantage in re-using old glass, additional energy is saved with the
present invention because the glass element of new solar panels are not
shipped to a central facility to be built into solar panels, and then
shipped again to a remote location for installation, as in the current
solar panel production model. The major investment in solar panel
production facilities, transport costs, increased part costs, and
overhead, is factored into the cost of each conventional solar panel
sold. Reducing panel part prices by using free glass, eliminating
expensive copper collector plates and decentralizing production can
reduce solar panel prices considerably.

[0030]While the focus of this invention is re-using older waste IGUs, due
to minor defects and production errors in the industry, new IGUs are
sometimes also available for purchase at next to no cost. Most used or
excess IGUs are disposed of by glass industry at a cost for disposal. For
example, those persons willing to haul the used or excess waste glass
away are often given that glass for free or at a very minor cost. This
method of creating solar panels can potentially create a market for
currently wasted glass, while at the same time reducing the cost of solar
panels to the consumer and creating low tech green jobs.

[0031]Referring to the drawings in more detail, connection pipelines 8
inter-connect the circulation passage between the panes of glass
containing water or some other suitable liquid for heat transfer, carry
the liquid from the solar panel 4 through a circulation pump 10, into a
storage tank 12 and the pipelines form a loop back to the solar panel
array. The pump 10 will run until instructed to turn off by the
controller. The controller may respond to a photovoltaic panel which can
sense when solar energy is present or to some other command. The storage
tank 12 may also be connected to a boiler or water heater powered by
another energy source. Hotter water introduced to the water storage tank
12 rises and cooler water sinks so that removing water from the lower
portion of the water column in tank 12 and then sending it to the solar
array 4 and returning it to the tank 12 in a warmer condition tends to
concentrate the heat energy collected.

[0032]The circulation pump 10 provides direct fluid circulation interface
with the solar panels 4 and the storage tank 12, and gives operational
control with on and off options over the solar system to advantageously
turn the system on in sunny conditions and off in less sunny conditions.
The liquid is thus cycled via a loop through the conduit 6 from the water
tank 12 as the heat energy is concentrated. In a preferred embodiment,
the conduit 6 will be coiled throughout the space 28 between the panes
16, 22. A differential controller device compares the temperature of the
solar array and the temperature of the hot water tank. Should the
temperature of the solar panel array become similar to the hot water
tank's temperature the controller device turns the power to the
circulation pump `off.` Should the controller device later determine that
the panel array is hotter than the water in the storage tank, the
controller turns the circulation pump back `on.`

[0033]FIG. 1 depicts a schematic environmental view of a solar panel 4
array, circulation pump 10, controller, and water tank 12. The water tank
may be a typical electric- or gas-powered water heater unit, or another
type of water storage device. The system may optionally contain a heat
exchanger if the fluid inside of the pipes 8 is not useable tap water.
The system shown in FIG. 1 is a typical setup for a hot-water solar panel
system in a residence or other structure. However, due to the method of
transforming a used IGU into a solar panel 4, a cost savings can be
achieved and waste that would otherwise end up in a landfill is avoided.

II. Repurposed IGUs as Solar Panels

[0034]FIG. 2 depicts the various layers of a solar panel 4 after being
transformed from an IGU. The original IGU contained an interior glass
pane 16 and an exterior glass pane 22 sandwiched around an open space 28.
When the IGU is disassembled, the interior space 28 is fitted with a
conduit 6 containing at least two taps 20 or an alternative collector
element, allowing the conduit 6 to be interconnected to a loop system of
pipes. FIG. 2 depicts the interior pane 16 as containing a film 18
painted or affixed to the surface facing the interior space 28 between
the panes 16, 22. This film 18 may be a special long wave energy
absorbing coating material. The film or solar selective coating 18 may be
on any surface of either pane 16, 22 as demonstrated in FIGS. 4-7. The
heat energy absorbing material may be a black liquid or even a solid
poured black body, which in any case has a fluid channel to allow
circulation of the fluid though the energy absorbing element.

[0035]A layer of insulation 24 is placed against the exterior pane 22.
This foam insulation ensures that heat striking the solar panel 4 does
not escape through the exterior back of the glass panel 22 or the entire
panel 4. A backboard 30 is affixed to the bottom of the insulation 24 for
protection and to contain it within the assembly of the solar panel 4.

[0036]A frame 14 contains the entire assembly. The frame 14 is attached by
elastic mastic adhesive means 31, such as high temperature silicone
sealant to the edges of the solar panel 4 where the original gasket was
removed. The frame 14 is designed to contain all layers of the panel 4
and to provide a mechanically strong means to affix the entire panel 4 to
a roof or other portion of a structure or other mounting surface while
allowing for expansion of the space between the glass panes in case of
expansion on the heat absorbing element because of freezing conditions.

[0037]FIG. 3 is an isometric drawing of an IGU. The IGU is comprised of an
interior panel 16 and an exterior pane 22 with a space 28 between the two
panels. The panes 16, 22 are joined together by a gasket 26 made of a
rubber or other similar material. The gasket 26 is removed or opened from
one side, as demonstrated in FIG. 3. In the preferred embodiment, the
heat absorbing member with a fluid circulation conduit 6 is placed
between the panes 16, 22, and the remaining space 28 is filled with a
dark liquid fluid such as food grade glycol water mix with positively
charged carbon black in suspension or similarly suitable substance for
transferring heat to the conduit 6 without fear of freezing at normal
outside temperatures.

[0038]FIG. 4 is an isometric view showing the construction of the panel 4
as it would be viewed by the user. The layers presented in FIG. 2 are
present here as well. It should be noted that the conduit 6 shown in
FIGS. 2 and 4 could be replaced by merely filling the space 28 between
the panes 16, 22 with water or another liquid substance and merely piping
this liquid through the space and out the other side once heated.

[0039]The layout shown in FIGS. 2 and 4 may alternatively be assembled
with the film layer 18 on different or multiple faces of the glass panes
16, 22. Additionally, any embodiment may or may not contain a glycol
solution or similar fluid within the panel 4, whereby the conduit 6 with
a metal heat energy absorber plate is merely heated due to direct
radiation from the sun, rather than increased heat absorbed by the glycol
solution. However, using the glycol solution will generally be the
preferred method and may be used in conjunction with a metal plate where
convention of the liquid solution transfers heat energy to the conduit 6
to be removed from the panel and sent to the storage tank.

III. Operation of the Preferred Embodiment

[0040]There are two basic techniques available from the described method
2. As discussed above, the first method involves flooding the internal
space 28 between the panes of glass 16, 22 with a heat transfer fluid,
such as liquid glycol/water solution, and ducting that heat transfer
fluid through the panel cooler and ducting it out at a warmer temperature
due to the heat energy gathered from exposure to the sun.

[0041]The advantages of this first technique, wherein the entire internal
space 28 is flooded with an antifreeze black heat transfer solution, is a
cost savings by reducing collector plate and fluid circulation parts
necessary to construct the overall panel 4. The heat transfer fluid could
be product hot water; however, a disadvantage to that solution would be
that tap water freezes in low atmospheric temperatures. Additionally
water pressure in the panel may fluctuate if attached to a city water
line, causing the panel to burst. A third problem with filling the space
with product water would be the growth of algae within the panel 4,
causing a loss of solar absorption.

[0042]As mentioned above, a thermally conductive fluid, such as a glycol,
oil, or an antifreeze/water mixture, could be used instead of product
water to prevent the above disadvantages. Using an internally contained
liquid would solve the problems of freezing, pressure, and algae growth,
but would require the additional inclusion of a heat exchanger to
transfer heat from the non-freezing liquid to useable water.
Alternatively, if freezing and pressure are not an issue, the upper
interior pane 16 could be painted with a black selective paint to create
a hot body while blocking light from the panel which would prevent moat
algae growth in a product water system.

[0043]The steps necessary to perform this first technique are as follows:
first, a spoiled or new IGU comprised of an interior 16 and exterior 22
pane sealed with a gasket 26 is disassembled and perhaps thoroughly
cleaned. Two parallel edges of the IGU are selected as the "top" and
"bottom" and the former exterior pane 22 is marked as such. A plurality
of holes may be drilled through the sealed rubber gasket 26 on the top
and bottom edges of the IGU. The vertical edges perpendicular to the
"top" and "bottom" edges chosen earlier are affixed with silicone or a
similar product to seal any leaks that may have appeared in these edges.
Pipe attachments are sealed into the top and bottom edges, which are then
also sealed with silicone or another sealant 31. All edges are affixed
with an extruded frame member 14. If desired, the faces of the panes 16,
22 can be painted with a black selective paint to increase the ability to
absorb solar radiation. An insulation layer 24 is placed against the
exterior pane 22 and is sealed with a backing cover 30. The panel can
then be installed on a structure. Water or another suitable liquid is
piped into the panel 4 via pipe taps extending through the seal 26
located on the top and bottom of the panel 4, the taps being connected to
the loop piping system 8. The liquid will be heated inside of the panel 4
and piped out the other end, where the heat energy will be circulated
throughout the system back to the storage tank to be concentrated due to
stratification of the cooler water going to the bottom of the storage
tank and hotter water rising to the top of the storage tank.

[0044]The second technique available using the described method is to
leave open one side of the IGU and insert a hollow conduit 6 or black
body device to absorb solar radiation, and provide a duct to pass heat
transfer fluid through the panel, without flooding the entire space
between. This is the example shown in FIGS. 2 and 4. The conduit 6 is
placed between the two panes of glass 16, 22 and the taps 20 are
connected to the system's liquid pipe lines 8. Again the panes 16, 22
surfaces may be painted black to increase solar radiation absorption.
Water or another heat transfer liquid are heated within the conduit or
black body and piped through the system in the same manner as performed
in the first technique.

[0045]It should be noted that if a reflective film was initially found on
any surface of either pane 16, 22, that surface should be pointed to face
in the direction of the back of the panel. In other words, the reflective
surface should be pointed away from the sun on the internal pane 16. Such
reflective films prevent solar radiation from being absorbed and should
be placed where the effect of that film is nullified.

IV. Business Method Embodiment

[0046]A low tech "Cottage Industry Solar Shop" business method and system
to re-use waste IGUs consists of the following: 1. Researching,
developing, documenting and patenting the best possible design for
converting used wasted IGUs into useful thermal solar panels; 2. Training
people to convert the old glass units into new solar panels using a well
defined system; 3. Training licensees of the technology in how to install
such thermal solar systems; 4. Licensing patented IGU conversion
technology, quality control systems and trademarks to such trained
individuals; 5. Providing specific unique parts such as custom extruded
and miter cut-to-length aluminum frame parts ordered to convert specific
used glass units into a new solar panel via an online store; 6. Develop
and operate a central online store and facility,
(CottageIndustrySolar.com) which ships the mitered, cut-to-length
aluminum frame parts, glycol, silicone mastic, and other custom pieces as
an IGU conversion kit; 7. Provides other specialized conversion elements
to the remote licensee; 8. Provide National Solar Rating Certification
certificates based upon licensees using the licensed procedures and
quality control procedures; 9. Solar ratings based upon BTUs/square inch
of panel aperture provide for tax credits for the consumer; 10. Provide a
warranty assurance program for all panels created by trained licensees;
11. Facilitate and promote an affordable franchise licensing business
methods for construction of new solar panels from used glass units and
certify the installation thereof; 12. Provide IGU conversion procedures
and parts for sale online to the general public, less rating certificates
and trademark licensing.

[0047]The above disclosed scenario reduces the energy footprint of solar
panel manufacturing dramatically while also presenting economic
opportunity for many people to use low tech tools and licensed techniques
to produce and install thermal solar systems in remote locations. Window
replacement firms, glass companies and waste disposal companies might
find an additional income stream by recycling the used glass they are
already wasting or a market for used glass might develop stopping the
wasteful disposal of all that glass. There is a lot of profit to be made
in producing new solar panels to be sold or installed. Mom and Pop
"cottage industry solar shops" will present a very green business
opportunity that ordinary persons can launch in their garages with a
minimum of specialized tools and a minimal investment for training and
setting up shop. The combination of re-using wasted IGUs, creating
cheaper thermal solar panels, reducing the energy used for the shipping
of heavy glass to and from a central location, the economic benefits and
the long term energy savings of an installed base of these converted IGU
solar panels represents a tremendous green potential to the United
States.

[0048]It is to be understood that while certain aspects of the disclosed
subject matter have been shown and described, the disclosed subject
matter is not limited thereto and encompasses various other embodiments
and aspects. The above-mentioned steps and components are not meant to
limit the use or organization of the present invention. The steps for
performing the method may be performed in any logical method and in any
logical order. The purpose of the invention is to use waste IGUs in the
best possible configuration to create inexpensive thermal solar panels.